Land vehicles incorporating monocoques and modular mold systems for making the same

ABSTRACT

In certain embodiments, an electric vehicle includes a front cage, a rear floor, an intermediate section, a utility cabinet, and a flatbed. In other embodiments, an electric vehicle includes a front cage, a rear floor, an intermediate section, and a flatbed. In some embodiments, the front cage at least partially defines an operator cabin, the rear floor is positioned rearward of the front cage in a longitudinal direction, and the intermediate section is disposed at least partially between the front cage and the rear floor in the longitudinal direction.

CROSS-REFERENCE TO RELATED APPLICATION(S)

The present application is a continuation of, and claims priority to,U.S. application Ser. No. 17/745,434, which was filed on May 16, 2022,and which is a continuation-in-part application of, and claims thepriority benefit of, U.S. application Ser. No. 17/716,687, which wasfiled on Apr. 8, 2022, and which is a continuation of U.S. applicationSer. No. 17/552,718, which issued as U.S. Pat. No. 11,299,208 on Apr.12, 2022, and which is a continuation application of U.S. applicationSer. No. 17/142,766, which issued as U.S. Pat. No. 11,220,297 on Jan.11, 2022, and which claims priority to, and the benefit of, U.S.Provisional App. Ser. No. 62/957,577 entitled “SYSTEMS AND METHODS FORMANUFACTURING LAND VEHICLES,” which was filed on Jan. 6, 2020. Thecontents of those applications are incorporated by reference herein intheir entireties.

TECHNICAL FIELD

The present disclosure generally relates to land vehicles and methods ofmaking land vehicles, and, more particularly, to utility and delivervehicles and methods of making utility and delivery vehicles.

BACKGROUND

Current systems and methods for manufacturing utility and deliveryvehicles suffer from a variety of drawbacks and limitations. For thosereasons, among others, there remains a need for further improvements inthis technological field.

SUMMARY

The present disclosure may comprise one or more of the followingfeatures and combinations thereof.

According to one aspect of the present disclosure, an electric vehiclemay include a front cage, a rear floor, an intermediate section, autility cabinet, and a flatbed. The front cage may at least partiallydefine an operator cabin. The rear floor may be positioned rearward ofthe front cage in a longitudinal direction. The intermediate section maybe disposed at least partially between the front cage and the rear floorin the longitudinal direction. The utility cabinet may include aplurality of drawers accessible from a utility space located outside theoperator cabin. The flatbed may be at least partially defined by therear floor. The flatbed may be open to the ambient environment anddefine the utility space.

In some embodiments, the utility cabinet may be arranged at leastpartially between the front cage and the rear floor in the longitudinaldirection, and when one or more of the plurality of drawers is in aclosed state, the one or more of the plurality of drawers in the closedstate may be aligned with the intermediate section in the longitudinaldirection. When one or more of the plurality of drawers is in an openedstate, the one or more of the plurality of drawers in the opened statemay extend rearward in the longitudinal direction into the utilityspace.

In some embodiments, the utility cabinet may extend forward in thelongitudinal direction to the front cage. The utility cabinet may extendat least partially into the operator cabin. Additionally, in someembodiments, the utility cabinet may directly contact arearwardly-facing exterior wall of the front cage that is interconnectedwith a roof of the front cage, and the exterior wall, the roof, and anuppermost surface of the utility cabinet in a vertical direction maycooperate to define a storage space accessible from the utility space.

In some embodiments, the utility cabinet may be arranged at leastpartially between the front cage and the rear floor in the longitudinaldirection, the intermediate section may include an alcove aligned withthe utility cabinet in the longitudinal direction, the alcove may definean opening into the intermediate section in a lateral directionperpendicular to the longitudinal direction, and the opening may beclosed off from the operator cabin. Additionally, in some embodiments,the flatbed may include a bench arranged in the utility space that issupported by the rear floor, and the plurality of drawers of the utilitycabinet may be disposed above the bench in a vertical direction topermit opening and closing of the plurality of drawers withoutinterference with the bench. In some embodiments still, movement of thevehicle may be driven by one or more electric motors, the vehicle mayinclude a monocoque that at least partially defines the front cage, therear floor, the intermediate section, and the flatbed, and the monocoquemay be formed from composite materials.

In some embodiments, the flatbed may include (i) first sidewall thatextends upwardly away from the rear floor in a vertical direction, (ii)a second sidewall arranged opposite the first sidewall that extendsupwardly away from the rear floor in the vertical direction, (iii) arear gate that extends between the first sidewall and the secondsidewall in a lateral direction perpendicular to the longitudinaldirection to at least partially close off the utility space, (iv) afirst guide rail interconnected with the first sidewall that extendsupwardly away from the first sidewall in the vertical direction todefine a first slot between the first sidewall and the first guide rail,and (v) a second guide rail interconnected with the second sidewall thatextends upwardly away from the second sidewall in the vertical directionto define a second slot between the second sidewall and the second guiderail. The flatbed may include (vi) a rear bumper extending rearwardly inthe longitudinal direction away from the rear gate and (vii) a vicemounted to the rear bumper.

According to another aspect of the present disclosure, an electricvehicle may include a front cage, a rear floor, an intermediate section,and a flatbed. The front cage may at least partially define an operatorcabin having a roof. The rear floor may be positioned rearward of thefront cage in a longitudinal direction. The intermediate section may bedisposed at least partially between the front cage and the rear floor inthe longitudinal direction. The flatbed may be at least partiallydefined by the rear floor. The flatbed may be open to the ambientenvironment and define a utility space accessible from a rear end of thevehicle. The flatbed may include a first sidewall that extends upwardlyaway from the rear floor in a vertical direction to at least partiallydefine the utility space and a second sidewall arranged opposite thefirst sidewall that extends upwardly away from the rear floor in thevertical direction to at least partially define the utility space. Theintermediate section may include a reinforcement beam that isinterconnected with the roof at one end thereof and interconnected withone of the first sidewall and the second sidewall at another end thereofopposite the one end.

In some embodiments, the reinforcement beam may extend oblique to theone of the first sidewall and the second sidewall to define an obtuseangle between the reinforcement beam and the one of the first sidewalland the second sidewall. The reinforcement beam may at least partiallydefine an alcove of the intermediate section that is disposed at leastpartially between the front cage and the rear floor in the longitudinaldirection, and the alcove may define an opening into the intermediatesection in a lateral direction perpendicular to the longitudinaldirection. The flatbed may include a first guide rail interconnectedwith the first sidewall that extends upwardly away from the firstsidewall in the vertical direction to define a first slot between thefirst sidewall and the first guide rail and a second guide railinterconnected with the second sidewall that extends upwardly away fromthe second sidewall in the vertical direction to define a second slotbetween the second sidewall and the second guide rail, and at least oneof the first guide rail and the second guide rail may be directlyinterconnected with the reinforcement beam. The flatbed may include arear gate that extends between the first sidewall and the secondsidewall in a lateral direction perpendicular to the longitudinaldirection to at least partially close off the utility space, a rearbumper extending rearwardly in the longitudinal direction away from therear gate, and a vice mounted to the rear bumper.

In some embodiments, the electric vehicle may include a utility cabinetincluding a plurality of drawers accessible from the utility space, theutility cabinet may be arranged at least partially between the frontcage and the rear floor in the longitudinal direction, and the utilitycabinet may extend forward in the longitudinal direction to the frontcage. The utility cabinet may extend at least partially into theoperator cabin. The utility cabinet may directly contact arearwardly-facing exterior wall of the front cage that is interconnectedwith the roof of the front cage, and the exterior wall, the roof, and anuppermost surface of the utility cabinet in the vertical direction maycooperate to define a storage space accessible from the utility space.

According to yet another aspect of the present disclosure, an electricvehicle may include a front cage, a rear floor, an intermediate section,a utility cabinet, and a flatbed. The front cage may at least partiallydefine an operator cabin having a roof. The rear floor may be positionedrearward of the front cage in a longitudinal direction. The intermediatesection may be disposed at least partially between the front cage andthe rear floor in the longitudinal direction. The utility cabinet mayinclude a plurality of drawers accessible from a utility space locatedoutside the operator cabin. The flatbed may be at least partiallydefined by the rear floor. The flatbed may be open to the ambientenvironment and define the utility space. The flatbed may include afirst sidewall that extends upwardly away from the rear floor in avertical direction to at least partially define the utility space and asecond sidewall arranged opposite the first sidewall that extendsupwardly away from the rear floor in the vertical direction to at leastpartially define the utility space. The intermediate section may includea reinforcement beam that is interconnected with the roof at one endthereof and interconnected with one of the first sidewall and the secondsidewall at another end thereof opposite the one end. The reinforcementbeam may extend oblique to the one of the first sidewall and the secondsidewall to define an obtuse angle between the reinforcement beam andthe one of the first sidewall and the second sidewall.

These and other features of the present disclosure will become moreapparent from the following description of the illustrative embodiments.

BRIEF DESCRIPTION OF THE FIGURES

The invention described herein is illustrated by way of example and notby way of limitation in the accompanying figures. For simplicity andclarity of illustration, elements illustrated in the figures are notnecessarily drawn to scale. For example, the dimensions of some elementsmay be exaggerated relative to other elements for clarity. Further,where considered appropriate, reference labels have been repeated amongthe figures to indicate corresponding or analogous elements.

FIG. 1 depicts side elevation views of a number of electric vehiclesthat may be included in an electric vehicle line according to certainembodiments of the disclosure;

FIG. 2 is a perspective view of a monocoque or unibody that may beincorporated into any electric vehicle of the disclosure;

FIG. 3 is a partially exploded assembly view of an electric vehicleaccording to at least one embodiment of the disclosure;

FIG. 4 is a partial schematic rear end view of a conventional deliveryvehicle;

FIG. 5 is a partial schematic rear end view of a delivery vehicleaccording to at least one embodiment of the disclosure;

FIG. 6 is a table illustrating United States standard vehicle classes bygross vehicular weight rating (GVWR);

FIG. 7 is a partial schematic depiction of a composite structure thatmay be used to form a monocoque or unibody of any electric vehicle ofthe disclosure;

FIG. 8 is a diagrammatic depiction of at least one modular mold systemaccording to certain embodiments of the disclosure;

FIG. 9 is a perspective view of a monocoque system formed from a numberof mold units included in the at least one modular mold system of FIG. 8;

FIG. 10 is a simplified flowchart of a method of forming a monocoque ofan electric vehicle using one modular mold system according to oneembodiment of the disclosure;

FIG. 11 is a simplified flowchart of one portion of another method offorming a monocoque of an electric vehicle using one modular mold systemaccording to another embodiment of the disclosure;

FIG. 12 is a diagrammatic view of another portion of the method of FIG.11 ;

FIG. 13 is a simplified flowchart of a method of forming multiplemonocoques of electric vehicles using at least one modular mold systemaccording to yet another embodiment of the disclosure;

FIG. 14 is a rear perspective view of one of the electric vehiclesdepicted in FIG. 1 ; and

FIG. 15 is a side elevation view of another one of the electric vehiclesdepicted in FIG. 1 .

DETAILED DESCRIPTION OF ILLUSTRATIVE EMBODIMENTS

While the concepts of the present disclosure are susceptible to variousmodifications and alternative forms, specific embodiments thereof havebeen shown by way of example in the drawings and will be describedherein in detail. It should be understood, however, that there is nointent to limit the concepts of the present disclosure to the particularforms disclosed, but on the contrary, the intention is to cover allmodifications, equivalents, and alternatives consistent with the presentdisclosure and the appended claims.

References in the specification to “one embodiment,” “an embodiment,”“an illustrative embodiment,” etc., indicate that the embodimentdescribed may include a particular feature, structure, orcharacteristic, but every embodiment may or may not necessarily includethat particular feature, structure, or characteristic. Moreover, suchphrases are not necessarily referring to the same embodiment. Further,when a particular feature, structure, or characteristic is described inconnection with an embodiment, it is submitted that it is within theknowledge of one skilled in the art to effect such feature, structure,or characteristic in connection with other embodiments whether or notexplicitly described. Additionally, it should be appreciated that itemsincluded in a list in the form of “at least one A, B, and C” can mean(A); (B); (C); (A and B); (A and C); (B and C); or (A, B, and C).Similarly, items listed in the form of “at least one of A, B, or C” canmean (A); (B); (C); (A and B); (A and C); (B and C); or (A, B, and C).

In the drawings, some structural or method features, such as thoserepresenting devices, modules, instructions blocks and data elements,may be shown in specific arrangements and/or orderings for ease ofdescription. However, it should be appreciated that such specificarrangements and/or orderings may not be required. Rather, in someembodiments, such features may be arranged in a different manner and/ororder than shown in the illustrative figures. Additionally, theinclusion of a structural or method feature in a particular figure isnot meant to imply that such feature is required in all embodiments and,in some embodiments, may not be included or may be combined with otherfeatures.

In some embodiments, schematic elements used to represent blocks of amethod may be manually performed by a user. In other embodiments,implementation of those schematic elements may be automated using anysuitable form of machine-readable instruction, such as software orfirmware applications, programs, functions, modules, routines,processes, procedures, plug-ins, applets, widgets, code fragments and/orothers, for example, and each such instruction may be implemented usingany suitable programming language, library, application programminginterface (API), and/or other software development tools. For instance,in some embodiments, the schematic elements may be implemented usingJava, C++, and/or other programming languages. Similarly, schematicelements used to represent data or information may be implemented usingany suitable electronic arrangement or structure, such as a register,data store, table, record, array, index, hash, map, tree, list, graph,file (of any file type), folder, directory, database, and/or others, forexample.

Further, in the drawings, where connecting elements, such as solid ordashed lines or arrows, are used to illustrate a connection,relationship, or association between or among two or more otherschematic elements, the absence of any such connection elements is notmeant to imply that no connection, relationship, or association canexist. In other words, some connections, relationships, or associationsbetween elements may not be shown in the drawings so as not to obscurethe disclosure. In addition, for ease of illustration, a singleconnecting element may be used to represent multiple connections,relationships, or associations between elements. For example, where aconnecting element represents a communication of signals, data orinstructions, it should be understood by those skilled in the art thatsuch element may represent one or multiple signal paths (e.g., a bus),as may be needed, to effect the communication.

Referring now to FIG. 1 , an illustrative line 100 of land vehiclesincludes a plurality of land vehicles. In the illustrative embodiment,the land vehicle line 100 includes, but is not limited to, atwo-passenger flatbed utility vehicle 110, a 650 cubic foot capacitydelivery vehicle 120, a 1000 cubic foot capacity delivery vehicle 130, asix-passenger flatbed utility vehicle 140, and a 1200 cubic footcapacity delivery vehicle 150. However, in some embodiments, the landvehicle line 100 may include any vehicle having a capacity within aparticular range, such as a range of from 400 cubic feet to 1400 cubicfeet, for example. In keeping with industry terminology, the phrase“cubic foot capacity” may be shortened or abbreviated herein to simply“cube.” It should be appreciated that the phrase “cubic foot capacity”as contemplated herein may refer to a storage volume or storage capacityof a particular land vehicle. In any case, as will be apparent from thediscussion that follows, one or more vehicles of the vehicle line 100may be manufactured using the systems and methods described herein.

In the illustrative embodiment, each of the vehicles included in thevehicle line 100 (i.e., each of the vehicles 110, 120, 130, 140, 150)includes a monocoque or unibody 200 (see FIG. 2 ) supporting wheels(e.g., wheels 112, 122, 132, 142, 152) to permit movement of theparticular vehicle relative to an underlying surface in use thereof. Asdescribed herein, the monocoque 200 is a single-piece, monolithicstructure unsupported by an internal chassis. The monocoque 200 includesa front cage 210 defining an operator cabin 212 and a rear floor 220positioned rearward of the front cage 210. The monocoque 200illustratively has a composite construction (e.g., the compositestructure 700 shown in FIG. 7 ) such that each of the front cage 210 andthe rear floor 220 are formed from one or more composite materials, asdescribed in greater detail below.

At least some of the vehicles (e.g., the vehicles 110, 140) of theillustrative line 100 may be embodied as, included in, or otherwiseadapted for use with, electric utility vehicles. Furthermore, at leastsome of the vehicles (e.g., the vehicles 120, 130, 150) of theillustrative line 100 may be embodied as, included in, or otherwiseadapted for use with, electric vehicles having enclosed stowagecompartments. Of course, in other embodiments, it should be appreciatedthat the vehicles of the line 100 may be embodied as, included in, orotherwise adapted for use with, other suitable vehicles.

It should be appreciated each of the vehicles of the illustrative line100 may be employed in a variety of applications. In some embodiments,one or more vehicles of the line 100 may be embodied as, or otherwiseincluded in, a fire and emergency vehicle, a refuse vehicle, a coachvehicle, a recreational vehicle or motorhome, a municipal and/or servicevehicle, an agricultural vehicle, a mining vehicle, a specialty vehicle,an energy vehicle, a defense vehicle, a port service vehicle, aconstruction vehicle, and a transit and/or bus vehicle, just to name afew. Additionally, in some embodiments, one or more vehicles of the line100 may be adapted for use with, or otherwise incorporated into,tractors, front end loaders, scraper systems, cutters and shredders, hayand forage equipment, planting equipment, seeding equipment, sprayersand applicators, tillage equipment, utility vehicles, mowers, dumptrucks, backhoes, track loaders, crawler loaders, dozers, excavators,motor graders, skid steers, tractor loaders, wheel loaders, rakes,aerators, skidders, bunchers, forwarders, harvesters, swing machines,knuckleboom loaders, diesel engines, axles, planetary gear drives, pumpdrives, transmissions, generators, and marine engines, among othersuitable equipment.

In the illustrative embodiment, each of the vehicles of the line 100includes one or more electric motors (not shown) capable of generatingrotational power that may be transmitted to the wheels to drive movementof the vehicle. As such, each of the illustrative vehicles is embodiedas, or otherwise includes, an electric vehicle. Details regarding theelectric motor(s) included in each vehicle and associated powertrainand/or suspension components are described in U.S. patent applicationSer. No. 17/142,814, the contents of which are incorporated herein byreference in their entirety.

Each of the vehicles of the illustrative line 100 does not include aninternal combustion engine or powerplant, at least in some embodiments.Furthermore, each of the vehicles of the illustrative line 100 does notinclude an engine or powerplant housed by the front cage 210 andpositioned above an underside 214 of the monocoque 200. Instead, asdescribed in U.S. patent application Ser. No. 17/142,814, multipleelectric motors or powerplants are removably coupled to the underside214 of the monocoque 200 of each vehicle of the illustrative line 100.

It should be appreciated that the vehicles of the illustrative vehicleline 100 may each include one or more features that improve theexperience of the driver, the owner, and/or maintenance personnel. Suchfeatures may include, but are not limited to, a low floor, a modularbattery system, air springs and/or air ride features, an independentrear suspension, an independent front suspension, thermal batterymanagement capability, flexible shelving options, desirable driversightlines, LED lighting, telematics/driver feedback, features tofacilitate maintenance, an aerodynamic body, and advanced safetysystems. Further details regarding at least some of these features areprovided herein.

Referring now to FIG. 2 , in addition to the front cage 210 and the rearfloor 220, at least in some embodiments, the monocoque 200 includes anintermediate section 230 arranged between the front cage 210 and therear floor 220. The intermediate section 230 may form a portion of afloor section arranged forward of the rear floor 220. As described ingreater detail below with reference to FIG. 8 , each of the front cage210, the rear floor 220, and the intermediate section 230 may beassociated with, and formed with, a corresponding mold unit of a modularmold system (e.g., the system 800). Furthermore, as described in greaterdetail below with reference to FIG. 9 , the mold units of the modularmold system may be joined together to form a monocoque mold (e.g., themonocoque mold 900) into which composite materials may be introduced toform the monocoque 200.

In the illustrative embodiment, the monocoque 200 combines what wouldtraditionally be formed from one or more separate structures (e.g., oneor more body components and one or more frame components) into asingle-piece, monolithic structure. As such, any vehicle of the presentdisclosure incorporating the monocoque 200 does not include an internalchassis or frame structure that supports separate body components (e.g.,panels, doors, etc.). Due at least in part to consolidation of body andframe components into an integrally-formed structure, the illustrativemonocoque 200 may be associated with, or otherwise facilitate, improvedmanufacturability and/or simplified maintenance compared to otherconfigurations.

Depending on the particular vehicle type and monocoque configuration,one or more dimensions of the intermediate section 230 of the monocoque200 may vary. In one example, the intermediate section 230 may have afirst length associated with, and defined by, a small intermediatesection mold unit (e.g., the mold unit 832 shown in FIG. 8 ). In thatexample, the first length of the intermediate section 230 may at leastpartially define a stowage compartment of a 650 cubic feet deliveryvehicle (e.g., the vehicle 120). In another example, the intermediatesection 230 may have a second length associated with, and defined by, amedium intermediate section mold unit (e.g., the mold unit 834 shown inFIG. 8 ). In that example, the second length of the intermediate section230 may at least partially define a stowage compartment of a 1000 cubicfeet delivery vehicle (e.g., the vehicle 130). In yet another example,the intermediate section 230 may have a third length associated with,and defined by, a large intermediate section mold unit (e.g., the moldunit 836 shown in FIG. 8 ). In that example, the third length of theintermediate section 230 may at least partially define a stowagecompartment of a 1200 cubic feet delivery vehicle (e.g., the vehicle150).

Furthermore, depending on the particular vehicle type and monocoqueconfiguration, the intermediate section 230 of the monocoque 200 may beomitted entirely. In such embodiments, the front cage 210 and the rearfloor 220 may be integrally-formed as a single-piece, monolithicstructure without the intermediate section 230 interposed therebetween.It should be appreciated that the utility vehicles 110 and 140 may eachinclude a monocoque formed without the intermediate section 230, atleast in some embodiments.

Referring now to FIG. 3 , a vehicle 300 incorporates the monocoque 200with the intermediate section 230 arranged between the front cage 210and the rear floor 220. Additionally, the vehicle 300 includes a cabhood 302 arranged above the front cage 210 to enclose the operator cabin212 and a stowage compartment 310 arranged rearward of the front cage210 and the cab hood 302. In the illustrative embodiment, the stowagecompartment 310 is at least partially defined by the intermediatesection 230 and the rear floor 220 and has a roof 312 and sidewalls 314.The illustrative vehicle 300 may be similar to any one of the vehicles120, 130, 150 discussed above, at least in some embodiments.

Because the monocoque 200 has a composite construction as indicatedabove, it should be appreciated that any vehicle described herein thatincorporates the monocoque 200 (e.g., any of the vehicles 110, 120, 130,140, 150, 300, 500) incorporates a composite structure (e.g., thestructure 700 shown in FIG. 7 ). In the case of the vehicle 300, each ofthe intermediate section 230, the roof 312, and the sidewalls 314 isformed from composite materials and has a composite structure, at leastin some embodiments. In those embodiments, each of the intermediatesection 230, the roof 312, and the sidewalls 314 does not includemetallic material.

Referring now to FIG. 4 , a prior art delivery vehicle 400 includes astowage compartment 410. The stowage compartment 410 includes a floor412, a pair of sidewalls 414, a ceiling 416, and a refrigeration unit418 at least partially housed by the stowage compartment 410 andconfigured to cool the stowage compartment 410. The rear end of thevehicle 400 includes a landing 404 and a step 406 that leads to thefloor 412 of the stowage compartment 410.

As depicted in FIG. 4 , the landing 404 has a landing height 424 aboveground level 402 and the step 406 has a step height 426 above thelanding 404. The floor 412 has a floor height 422 above the ground level402 that includes both the landing height 424 and the step height 426.Typically, the landing height 424 is about 25 inches, the step height426 is about ten inches, and the floor height 422 is about 35 inches.

Referring now to FIG. 5 , a delivery vehicle 500 may include a monocoque(e.g., the monocoque 200) described above with reference to FIG. 2 .Furthermore, in some embodiments, the vehicle 500 may be similar to oneor more of the vehicles 120, 130, 150 described above. In any case, theillustrative delivery vehicle 500 includes a stowage compartment 510having a floor 512, a pair of sidewalls 514, and a ceiling 516, as wellas a refrigeration unit 518 housed by the stowage compartment 510.Unlike the prior art delivery vehicle 400, however, the vehicle 500lacks a step corresponding to the step 406. As such, the floor 512 has afloor height 522 that substantially corresponds to, and may be equal to,the landing height 424. The floor height 522 may be less than thirtyinches, such as in the range of 22 to 28 inches, for example. A pair ofwheel wells 530 formed within the stowage compartment 510 are offsetfrom one another by a separation distance 532. In certain embodiments,the separation distance 532 may be about 50 inches.

In some cases, the prior art delivery vehicle 400 suffers from one ormore disadvantages not associated with the illustrative vehicle 500. Inone respect, the sidewalls 414 and the ceiling 416 of the prior artvehicle 400 are typically formed of metallic material such as aluminum,for example, which is a poor thermal insulator. As such, the compartment410 may be poorly insulated and have a tendency to adopt the temperatureof the ambient environment relatively quickly. That may be especiallythe case in the summer when radiant heat from the sun supplements theambient hot air to exacerbate the warming of the compartment 410. Incontrast, the sidewalls 514 and the ceiling 516 of the illustrativevehicle 500 are formed of composite materials, which exhibit superiorinsulating characteristics compared to metallic material such asaluminum. Accordingly, the compartment 510 is insulated from the ambientenvironment to a greater degree than the compartment 410. Thatinsulation may be particularly advantageous in cases in which thevehicle 500 is a refrigerated vehicle such as a food delivery vehicle,for instance. It should be appreciated that the insulating properties ofthe compartment 510 may ease the cooling burden on the refrigerationunit 518 and thereby increase performance of the refrigeration unit 518.Additionally, in certain circumstances, increased performance of therefrigeration unit 518 may enable the vehicle 500 to be provided with asmaller refrigeration unit 518 than would typically be required by theprior art vehicle 400.

Another drawback associated with the prior art vehicle 400 is theelevated nature of the floor 412 relative to the ground level 402. Itshould be appreciated that the elevated floor 412 is not merely a designchoice but rather a feature often necessitated to accommodate inclusionof the internal chassis or frame, the powertrain, and associatedcomponents. Put another way, to accommodate the mounting of aconventional internal combustion engine and other powertrain components(e.g., a transmission, transaxle, and/or a differential) to an internalchassis, the floor 412 is elevated above the ground level 402 by thefloor height 422. Consequently, the elevated floor 412 reduces thestorage capacity and/or volume of the stowage compartment 410 andrequires the provision of the step 406. Delivery personnel using thevehicle 400 must therefore step up onto the landing 404 and ascend thestep 406 in order to access the compartment 410.

The illustrative vehicle 500 obviates a number of the aforementioneddisadvantages by eliminating the necessity of the elevated floor 412.Due in part to the provision of the monocoque 200 as a single-piece,monolithically formed structure having a relatively lightweightcomposite construction, and due in part to the absence of powertraincomponents typically provided in other configurations (e.g., a centraldrive shaft beneath the underside 214 of the monocoque 200 that providesa rotational input to a differential), the floor 512 need not beelevated above the ground level like the floor 412. As a result, thevehicle 500 allows increased stowage capacity of the stowage compartment510 to be achieved without raising the ceiling 516. Moreover, because astep similar to the step 406 may be omitted from the vehicle 500, thefloor height 522 corresponds to the landing height 424 of theconventional vehicle 400, and delivery personnel may avoid the effort ofascending both the landing 404 and the step 406 to access the stowagecompartment 510 of the vehicle 500. Notably, it should be appreciatedthat a rear bumper of the vehicle 500 may be slightly lower than thefloor 512 and that delivery personnel may access the compartment 510 byfirst stepping on the rear bumper. In some embodiments, the rear bumpermay have a height of about 20 inches above the ground level, whereas thefloor 512 may have a height of about 25 inches above the ground level.

Referring now to FIG. 6 , in the United States, trucks are oftenclassified according to their gross vehicular weight rating (GVWR).Those truck classifications, the associated duty classifications, andthe corresponding GVWRs are illustrated in the table 600. In theillustrative embodiment, one or more of the vehicles 110, 120, 130, 140,150 has a GVWR (i.e., accounting for the weight of the truck when emptyand the payload carrying capacity of the truck when full) of between6,000 pounds and 19,800 pounds. In some embodiments, one or more of thevehicles 110, 120, 130, 140, 150 has a GVWR of between 10,001 pounds and14,000 pounds such that one or more of the vehicles 110, 120, 130, 140,150 is embodied as, or otherwise includes, a Class 3 truck. In oneparticular example, in some embodiments, the 1000 cubic foot capacityvehicle 130 weighs roughly 6,500 pounds when empty and has a 6,000 poundpayload capacity such that the vehicle 130 has a GVWR of about 12,500pounds. Of course, it should be appreciated that in other embodiments,the vehicle line 100 may include one or more vehicles in Class 3, one ormore vehicles in Class 4, and/or one or more vehicles in Class 5.

In some embodiments, the systems and methods described herein may findparticular utility in connection with delivery vehicles in Classes 3through 5. For example, the methods 1000, 1100, 1300 described below maybe utilized to form a monocoque for a delivery vehicle having a GVWRbetween 10,001 pounds and 19,500 pounds. The stowage capacity of such avehicle may be between 450 cubic feet and 1200 cubic feet. In certainembodiments, the stowage compartment (e.g., the compartment 510) of thevehicle may be isolated from the operator cabin (e.g., the operatorcabin 212) of the vehicle.

Referring now to FIG. 7 , any vehicle of the present disclosure includesa monocoque having the composite structure 700. In the illustrativeembodiment, the composite structure 700 incorporates one or morerelatively lightweight, low-density materials to impart a relativelylightweight construction to the vehicle. As discussed below, theillustrative composite structure 700 includes one or more of thefollowing: balsa wood, plastic, fiberglass, resin, Kevlar, honeycomb,and carbon fiber. The composite structure 700 does not include, and isnot formed from, metallic material, at least in some embodiments. Inthose embodiments, the monocoque (e.g., the monocoque 200) incorporatingthe composite structure 700 does not include metallic material.

The illustrative composite structure 700 includes a core 702 and a shell704 that at least partially surrounds the core 702. In the illustrativeembodiment, the core 702 is formed from balsa wood and/or one or more ofthe following composite, non-metallic materials: unidirectionalfiberglass, multi-directional fiberglass, Kevlar, carbon fiber, plastic,honeycomb, or other suitable composite, non-metallic materials. Ofcourse, in other embodiments, the core 702 may be formed from othersuitable materials to provide a relatively lightweight construction tothe composite structure 700. The illustrative shell 704 is formed fromfiberglass and resin. However, in other embodiments, the shell 704 maybe formed from other suitable materials. Additionally, in theillustrative embodiment, the composite structure 700 includes a laminatelayer 706 that at least partially covers the shell 704.

It should be appreciated that the composite structure 700 used to formthe monocoque of any vehicle of the present disclosure offers a numberof advantages over multi-piece metallic constructions of conventionalvehicles. In one respect, the single-piece monolithic structure formedwith the composite structure 700 has fewer parts and offers greaterstructural simplicity than vehicle constructions requiring multipleparts. In another respect, the structural simplicity afforded by thecomposite structure 700 may facilitate maintenance and improvestructural efficiency. In yet another respect, due to a lack of metallicmaterial, the composite structure 700 may minimize or eliminate rustand/or corrosion and thereby have a service life that exceeds theservice life of vehicles having conventional constructions. In someinstances, monocoques incorporating composite structures 700 consistentwith the teachings of the present disclosure may have service lives of20 years or more.

Referring now to FIGS. 8 and 9 , a modular mold system 800 (see FIG. 8 )includes a number of illustrative mold units that may be selected andarranged to form a monocoque system 900 (see FIG. 9 ). It should beappreciated that when arranged to form the monocoque system 900, theselected mold units of the modular system 800 are utilized to form amonocoque such as the above-described monocoque 200, for example.Furthermore, it should be appreciated that similar reference numerals inthe 800 and 900 series are used to designate corresponding features ofthe modular mold system 800 and the monocoque system 900.

The illustrative mold system 800 includes a front cage mold unit 810, arear floor mold unit 820, and a plurality of intermediate mold units 830having a small intermediate section mold unit 832, a medium intermediatesection mold unit 834, and a large intermediate section mold unit 836.As discussed below, each of the mold units 810, 820, 832, 834, 836 has amold cavity having a size and a shape corresponding to a correspondingfeature of the monocoque system 900 such that subsequent to introductionof the composite materials (e.g., the materials of the compositestructure 700) into the mold cavity, the corresponding feature of themonocoque system 900 will be formed. Accordingly, the front cage moldunit 810 includes a front cage mold cavity 912 that has a size and ashape corresponding to the front cage 910 of the monocoque system 900(and also the front cage 210). The rear floor mold unit 820 includes arear floor mold cavity 922 that has a size and a shape corresponding tothe rear floor 920 of the monocoque system 900 (and also the rear floor220). The intermediate mold units 832, 834, 836 include respectiveintermediate mold cavities 933, 935, 937 each having a size and a shapecorresponding to the respective intermediate section 932, 934, 936 ofthe monocoque system 900 (and also the intermediate section 230).

As evident from FIGS. 8 and 9 , each of the intermediate mold units 832,834, 836 is sized for positioning between the front cage mold unit 810and the rear floor mold unit 820 to form the monocoque system 900. Itshould be appreciated that any one of the intermediate mold units 832,834, 836 may be selected and arranged between the front cage mold unit810 and the rear floor mold unit 820 to form the monocoque system 900.Selection of the particular mold unit 832, 834, 836 is based on theconfiguration of the vehicle and the monocoque included therein, asfurther discussed below.

In the illustrative embodiment, the front cage mold cavity 912 of thefront cage mold unit 810 has an opening 914 at a rear end thereof (i.e.,the end closest to one of the intermediate sections 932, 934, 936 asshown in FIG. 9 ) to establish a fluidic coupling between the cavity 912and another component of the mold system 800. In some embodiments, afluidic coupling may be established between the front cage mold cavity912 and one of the intermediate mold cavities 933, 935, 937 when thefront cage mold unit 810 is arranged contiguously with one of thecorresponding intermediate mold units 832, 834, 836. Additionally, insome embodiments, a fluidic coupling may be established between thefront cage mold cavity 912 and the rear floor mold cavity 922 when thefront cage mold unit 810 is arranged contiguously with the rear floormold unit 820.

In the illustrative embodiment, the rear floor mold cavity 922 of therear floor mold unit 820 has an opening 924 at a front end thereof(i.e., the end closest to one of the intermediate sections 932, 934, 936as shown in FIG. 9 ) to establish a fluidic coupling between the cavity922 and another component of the mold system 800. Each of theintermediate mold cavities 933, 935, 937 of the intermediate mold units832, 834, 836 has an opening 938 at a front end thereof (i.e., the endclosest to the front cage 910 as shown in FIG. 9 ) and an opening 940 ata rear end thereof (i.e., the end closest to the rear floor 920 as shownin FIG. 9 ). When one of the intermediate mold units 832, 834, 836 isarranged contiguously with the front cage mold unit 810, a fluidiccoupling is established between the corresponding intermediate moldcavity 933, 935, 937 and the front cage mold cavity 912 via the openings914, 938. Additionally, when one of the intermediate mold units 832,834, 836 is arranged contiguously with the rear floor mold unit 820, afluidic coupling is established between the corresponding intermediatemold cavity 933, 935, 937 and the rear floor mold cavity 922 via theopenings 924, 940.

It should be appreciated that the front end of each of the illustrativeintermediate mold units 832, 834, 836 is configured for directconnection and attachment to the rear end of the front cage mold unit810. Furthermore, it should be appreciated that the rear end of each ofthe illustrative intermediate mold units 832, 834, 836 is configured fordirect connection and attachment to the front end of the rear floor moldunit 820. Consequently, when any one of the intermediate mold units 832,834, 836 is directly connected with the front cage mold unit 810 and therear floor mold unit 820, the front cage mold cavity 912, thecorresponding intermediate mold cavity 933, 935, 937, and the rear floormold cavity 922 are fluidically coupled to one another in a contiguousarrangement to establish a continuous monocoque mold cavity into whichcomposite materials may be introduced to form the monocoque as asingle-piece, monolithic structure.

It should also be apparent that the rear end of the illustrative frontcage mold unit 810 is configured for direct connection and attachment tothe front end of the rear floor mold unit 820. As a result, when thefront cage mold unit 810 is directly connected to the rear floor moldunit 820, the front cage mold unit 810 and the rear floor mold unit 820are fluidically coupled to one another in a contiguous arrangement toestablish a continuous monocoque mold cavity into which compositematerials may be introduced to form the monocoque as a single-piece,monolithic structure.

In the illustrative embodiment, the small intermediate section mold unit832 has a length L1 as suggested by FIG. 9 . The medium intermediatesection mold unit 834 has a length L2 that is greater than the lengthL1, at least in some embodiments. The large intermediate section moldunit 836 has a length L3 that is greater than the length L2 and thelength L1, at least in some embodiments.

In some embodiments, the small intermediate section mold unit 832 may beused to form the intermediate section 932 of the monocoque system 900such that the monocoque at least partially produced using the mold unit832 is included in a vehicle having a storage volume of 650 cubic feet(e.g., the vehicle 120). Additionally, in some embodiments, the mediumintermediate section mold unit 834 may be used to form the intermediatesection 934 of the monocoque system 900 such that the monocoque at leastpartially produced using the mold unit 834 is included in a vehiclehaving a storage volume of 1000 cubic feet (e.g., the vehicle 130). Insome embodiments still, the large intermediate section mold unit 836 maybe used to form the intermediate section 936 of the monocoque system 900such that the monocoque at least partially produced using the mold unit836 is included in a vehicle having a storage volume of 1200 cubic feet(e.g., the vehicle 150).

Referring now to FIG. 10 , an illustrative method 1000 of forming amonocoque (e.g., the monocoque 200) using a modular mold system (e.g.,the system 800) is depicted. The method 1000 corresponds to, or isotherwise associated with, performance of the blocks described below inthe illustrative sequence of FIG. 10 . It should be appreciated,however, that the method 1000 may be performed in one or more sequencesdifferent from the illustrative sequence. Furthermore, it should beappreciated that one or more of the blocks described below may beexecuted contemporaneously and/or in parallel with one another. In someembodiments, the method 1000 may be performed manually by one or moreoperators. In other embodiments, the method 1000 may be embodied as, orotherwise include, a set of instructions that are performed by anautomated control system.

The illustrative method 1000 begins with block 1002. In block 1002, theoperator(s) or the control system selects a land vehicle type or amonocoque configuration for a particular land vehicle. It should beappreciated that to perform block 1002, the operator(s) or the controlsystem may select any vehicle envisioned by the present disclosure orany monocoque configuration associated with a particular vehiclecontemplated by the present disclosure. From block 1002, the method 1000subsequently proceeds to block 1004.

In block 1004 of the illustrative method 1000, the operator(s) or thecontrol system selects a first mold unit of the modular mold systembased upon the selected vehicle type or monocoque configuration. In theillustrative embodiment, to perform block 1004, the operator(s) or thecontrol system selects the rear floor mold unit 820 of the modularsystem 800 in block 1006. However, in other embodiments, it should beappreciated that block 1004 may be performed by selecting (i) the smallintermediate section mold unit 832 (i.e., in block 1008), (ii) themedium intermediate section mold unit (i.e., in block 1010), or (iii)the large intermediate section mold unit 836 (i.e., in block 1012).Selection of one of the intermediate mold units 832, 834, 836 as thefirst mold unit is described in greater detail below with reference toFIG. 11 . In any case, from block 1004, the method 1000 subsequentlyproceeds to block 1014.

In block 1014 of the illustrative method 1000, the operator(s) or thecontrol system couples the selected first mold unit to the front cagemold unit 810 of the modular system 800. It should be appreciated thatto perform block 1014, the selected first mold unit (i.e., the rearfloor mold unit 820) is coupled to the front cage mold unit 810 suchthat the front cage mold cavity 912 is fluidly coupled to the rear floormold cavity 922 to at least partially establish a continuous monocoquemold cavity. Following performance of block 1014, the method 1000proceeds to block 1016.

In block 1016 of the illustrative method 1000, the operator(s) or thecontrol system introduces one or more composite materials (e.g., thecomposite materials included in the composite structure 700) into thecontinuous monocoque mold cavity formed in block 1014. Morespecifically, to perform block 1016, at least in some embodiments, theoperator(s) or the control system performs blocks 1018, 1020, and 1022.In block 1018, the operator(s) or the control system introduces one ormore composite materials into the continuous monocoque mold cavitywithout introducing metallic material into the cavity. In otherembodiments, however, block 1018 may be omitted from the method 1000. Inblock 1020, the operator(s) or the control system places a firstmaterial in the continuous monocoque mold cavity. The first material mayinclude balsa wood and/or plastic, at least in some embodiments. Inblock 1022, the operator(s) or the control system places a secondmaterial different from the first material in the continuous monocoquemold cavity. The second material may include fiberglass and resin, atleast in some embodiments. Following performance of block 1016, themethod 1000 proceeds to block 1024.

In block 1024 of the illustrative method 1000, the operator(s) or thecontrol system cures the one or more composite materials in thecontinuous monocoque mold cavity to form the monocoque. To perform block1024, the operator(s) or the control system may perform blocks 1026,1028, and 1030, at least in some embodiments. In block 1026, theoperator(s) or the control system forms a core (e.g., the core 702)including the first material introduced in block 1016. In block 1028,the operator(s) or the control system forms a shell (e.g., the shell704) including the second material introduced in block 1016 that atleast partially surrounds the core. In block 1030, the operator(s) orthe control system forms a laminate layer (e.g., the layer 706) that atleast partially covers the shell.

Referring now to FIGS. 11 and 12 , an illustrative method 1100 offorming a monocoque (e.g., the monocoque 200) using a modular moldsystem (e.g., the system 800) is depicted. The method 1100 correspondsto, or is otherwise associated with, performance of the blocks describedbelow in the illustrative sequence of FIGS. 11 and 12 . It should beappreciated, however, that the method 1100 may be performed in one ormore sequences different from the illustrative sequence. Furthermore, itshould be appreciated that one or more of the blocks described below maybe executed contemporaneously and/or in parallel with one another. Insome embodiments, the method 1100 may be performed manually by one ormore operators. In other embodiments, the method 1100 may be embodiedas, or otherwise include, a set of instructions that are performed by anautomated control system.

The illustrative method 1100 begins with block 1102. In block 1102, theoperator(s) or the control system selects a land vehicle type or amonocoque configuration for a particular land vehicle. It should beappreciated that to perform block 1102, the operator(s) or the controlsystem may select any vehicle envisioned by the present disclosure orany monocoque configuration associated with a particular vehiclecontemplated by the present disclosure. From block 1102, the method 1100subsequently proceeds to block 1104.

In block 1104 of the illustrative method 1100, the operator(s) or thecontrol system selects a first mold unit of the modular mold systembased upon the selected vehicle type or monocoque configuration. In theillustrative embodiment, to perform block 1104, the operator(s) or thecontrol system performs one of blocks 1106, 1108, and 1110. In block1106, the operator(s) or the control system selects the smallintermediate section mold unit 832. In block 1108, the operator(s) orthe control system selects the medium intermediate section mold unit834. In block 1110, the operator(s) or the control system selects thelarge intermediate section mold unit 836. Following performance of block1104, the method 1100 proceeds to block 1112.

In block 1112 of the illustrative method 1100, the operator(s) or thecontrol system selects a second mold unit of the modular system. In theillustrative embodiment, to perform block 1112, the operator(s) or thecontrol system performs block 1114. In block 1114, the operator(s) orthe control system selects the rear floor mold unit 820 of the modularsystem 800. From block 1112, the method 1100 subsequently proceeds toblock 1116.

In block 1116 of the illustrative method 1100, the operator(s) or thecontrol system couples the selected first mold unit to the front cagemold unit 810 of the modular system 800. It should be appreciated thatto perform block 1116, the selected first mold unit (i.e., one of theintermediate mold units 832, 834, 836) is coupled to the front cage moldunit 810 such that the front cage mold cavity 912 is fluidly coupled tothe corresponding intermediate mold unit cavity (i.e., one of thecavities 933, 935, 937) to at least partially establish a continuousmonocoque mold cavity. Following performance of block 1116, the method1100 proceeds to block 1118.

In block 1118 of the illustrative method 1100, the operator(s) or thecontrol system couples the selected first mold unit (i.e., one of theintermediate mold units 832, 834, 836) to the selected second mold unit(i.e., the rear floor mold unit 820). It should be appreciated that toperform block 1118, one of the intermediate mold units 832, 834, 836 iscoupled to the rear floor mold unit 820 such that the rear floor moldcavity 922 is fluidly coupled to the corresponding intermediate moldunit cavity (i.e., one of the cavities 933, 935, 937) to at leastpartially establish the continuous monocoque mold cavity. Followingperformance of block 1118, the method 1100 proceeds to block 1120.

In block 1120 of the illustrative method 1100, the operator(s) or thecontrol system introduces one or more composite materials (e.g., thecomposite materials included in the composite structure 700) into thecontinuous monocoque mold cavity formed in block 1118. Morespecifically, to perform block 1120, at least in some embodiments, theoperator(s) or the control system performs blocks 1122, 1124, and 1126.In block 1122, the operator(s) or the control system introduces one ormore composite materials into the continuous monocoque mold cavitywithout introducing metallic material into the cavity. In otherembodiments, however, block 1122 may be omitted from the method 1100. Inblock 1124, the operator(s) or the control system places a firstmaterial in the continuous monocoque mold cavity. The first material mayinclude balsa wood and/or plastic, at least in some embodiments. Inblock 1126, the operator(s) or the control system places a secondmaterial different from the first material in the continuous monocoquemold cavity. The second material may include fiberglass and resin, atleast in some embodiments. Following performance of block 1120, themethod 1000 proceeds to block 1202.

In block 1202 of the illustrative method 1100, the operator(s) or thecontrol system cures the one or more composite materials in thecontinuous monocoque mold cavity to form the monocoque. To perform block1202, the operator(s) or the control system may perform blocks 1204,1206 and 1208, at least in some embodiments. In block 1204, theoperator(s) or the control system forms a core (e.g., the core 702)including the first material introduced in block 1120. In block 1206,the operator(s) or the control system forms a shell (e.g., the shell704) including the second material introduced in block 1120 that atleast partially surrounds the core. In block 1208, the operator(s) orthe control system forms a laminate layer (e.g., the layer 706) that atleast partially covers the shell.

Referring now to FIG. 13 , an illustrative method 1300 of formingmultiple monocoques of land vehicles using at least one modular moldsystem is depicted. The method 1300 corresponds to, or is otherwiseassociated with, performance of the blocks described below in theillustrative sequence of FIG. 13 . It should be appreciated, however,that the method 1300 may be performed in one or more sequences differentfrom the illustrative sequence. Furthermore, it should be appreciatedthat one or more of the blocks described below may be executedcontemporaneously and/or in parallel with one another. In someembodiments, the method 1300 may be performed manually by one or moreoperators. In other embodiments, the method 1300 may be embodied as, orotherwise include, a set of instructions that are performed by anautomated control system.

The illustrative method 1300 begins with block 1302. In block 1302, theoperator(s) or the control system forms a first monocoque of a firstland vehicle. To perform block 1302, the operator(s) or the controlsystem forms the first monocoque of the first land vehicle using atleast one modular system (e.g., the system 800) in block 1304. In someembodiments, the first monocoque of the first land vehicle is formedusing only the front cage mold unit 810 and the rear floor mold unit 820of the modular system 800. In those embodiments, the first monocoque ofthe first land vehicle may be formed by performing the method 1000described above. In other embodiments, the first monocoque of the firstland vehicle is formed using the front cage mold unit 810, the rearfloor mold unit 820, and one of the intermediate mold units 832, 834,836. In those embodiments, the first monocoque of the first land vehiclemay be formed by performing the method 1100 described above. In anycase, following performance of block 1302, the method 1300 proceeds toblock 1306.

In block 1306 of the illustrative method 1300, the operator(s) or thecontrol system forms a second monocoque of a second land vehicle that isdifferent from the first land vehicle. To perform block 1306, theoperator(s) or the control system forms the second monocoque of thesecond land vehicle using at least one modular system (i.e., the system800) in block 1308. In embodiments in which the first monocoque of thefirst land vehicle is formed in block 1302 using only the front cagemold unit 810 and the rear floor mold unit 820 of the modular system 800(i.e., according to the method 1000), the second monocoque of the secondland vehicle is formed using the front cage mold unit 810, the rearfloor mold unit 820, and one of the intermediate mold units 832, 834,836 (i.e., according to the method 1100). In embodiments in which thefirst monocoque of the first land vehicle is formed in block 1302 usingthe front cage mold unit 810, the rear floor mold unit 820, and a firstone of the intermediate mold units 832, 834, 836 (i.e., according to themethod 1100), the second monocoque of the second land vehicle is formedusing the front cage mold unit 810, the rear floor mold unit 820, and asecond one of the intermediate mold units 832, 834, 836 that isdifferent from the first one. Regardless, from block 1306, the method1300 subsequently proceeds to block 1310.

In block 1310 of the illustrative method 1300, the operator(s) or thecontrol system forms a third monocoque of a third land vehicle that isdifferent from the first land vehicle and the second land vehicle. Toperform block 1310, the operator(s) or the control system forms thethird monocoque of the third land vehicle using at least one modularsystem (i.e., the system 800) in block 1310. In embodiments in which (i)the first monocoque of the first land vehicle is formed in block 1302using only the front cage mold unit 810 and the rear floor mold unit 820of the modular system 800 (i.e., according to the method 1000) and (ii)the second monocoque of the second land vehicle is formed in block 1306using the front cage mold unit 810, the rear floor mold unit 820, and afirst one of the intermediate mold units 832, 834, 836 (i.e., accordingto the method 1100), the third monocoque of the third land vehicle isformed using the front cage mold unit 810, the rear floor mold unit 820,and a second one of the intermediate mold units 832, 834, 836 that isdifferent from the first one. In embodiments in which (i) the firstmonocoque of the first land vehicle is formed in block 1302 using thefront cage mold unit 810, the rear floor mold unit 820, and a first oneof the intermediate mold units 832, 834, 836 (i.e., according to themethod 1100) and (ii) the second monocoque of the second land vehicle isformed in block 1306 using the front cage mold unit 810, the rear floormold unit 820, and a second one of the intermediate mold units 832, 834,836 that is different from the first one, the third monocoque of thethird land vehicle is formed using the front cage mold unit 810, therear floor mold unit 820, and a third one of the intermediate mold units832, 834, 836 that is different from the first one and the second one.

Referring now to FIG. 14 , the six-passenger flatbed utility vehicle 140shown in FIG. 1 is depicted in greater detail. It should be appreciatedthat the illustrative vehicle 140 is an electric vehicle as mentionedabove. In the illustrative embodiment, the vehicle 140 includes a frontcage 1410, a rear floor 1430, an intermediate section 1450, and aflatbed 1470. The front cage 1410 at least partially defines an operatorcabin 1412 of the vehicle 140. The rear floor 1430 is positionedrearward of the front cage 1410 in a longitudinal direction D1. Theintermediate section 1450 is disposed at least partially between thefront cage 1410 and the rear floor 1430 in the longitudinal directionD1. The flatbed 1470 is at least partially defined by the rear floor1430 and open to the ambient environment. The flatbed 1470 defines autility space 1472 that is located outside the operator cabin 1412 andaccessible from a rear end 1404 of the vehicle 140.

The illustrative vehicle 140 may be formed from the monocoque system 900and/or the modular mold system 800 described herein. The front cage 1410may be formed from the front cage mold unit 810, the rear floor 1430 andthe flatbed 1470 may be formed from the rear floor mold unit 820, andthe intermediate section 1450 may be formed from one of the intermediatemold units 832, 834, 836, at least in some embodiments. Additionally, insome embodiments, the front cage 1410 may be formed from the front cagemold unit 810 having the shape and structure of the mold unit 910, therear floor 1430 and the flatbed 1470 may be formed from the rear floormold unit 820 having the shape and structure of the mold unit 920, andthe intermediate section 1450 may be formed from one of the intermediatemold units 832, 834, 836 having the shape and structure of thecorresponding units 932, 934, 936.

In the illustrative embodiment, the vehicle 140 includes a utilitycabinet 1460 having drawers 1462 that are accessible from the utilityspace 1472. The utility cabinet 1460 is arranged at least partiallybetween the front cage 1410 and the rear floor 1430 in the longitudinaldirection D1. As such, in at least some embodiments, the utility cabinet1460 is aligned with the intermediate section 1450 in the longitudinaldirection D1. Additionally, in some embodiments, the utility cabinet1460 is included in, or otherwise forms a portion of, the intermediatesection 1450.

The illustrative utility cabinet 1460 extends forward (i.e., toward afront end 1402 of the vehicle 140) in the longitudinal direction D1 tothe front cage 1410. In some embodiments, the utility cabinet 1460extends at least partially into the operator cabin 1412. In suchembodiments, the operator cabin 1412 may define an interior space 1414(shown in phantom) that receives a portion of the utility cabinet 1460,and positioning of the utility cabinet 1460 in the interior space 1414may close off, or substantially close off, the interior space 1414 fromfluid communication with the utility space 1472.

In some embodiments, the utility cabinet 1460 extends forward in thelongitudinal direction D1 to the front cage 1410 such that the utilitycabinet 1460 is flush with, and/or in contact with, a wall 1416 of thefront cage 1410 that closes off, or substantially closes off, theoperator cabin 1412 from fluid communication with the utility space1472. In such embodiments, the utility cabinet 1460 may not extend intothe operator cabin 1412. In such embodiments, the utility cabinet 1460may be disposed entirely within the utility space 1472.

Each of the drawers 1462 of the utility cabinet 1460 are depicted inFIG. 14 in a closed state 1464. When the drawers 1462 are in the closedstate 1464, the drawers 1462 are aligned with the intermediate section1450 in the longitudinal direction D1. As suggested by FIG. 14 , wheneach of the drawers 1462 is in an opened state 1466 (shown in phantom),each of the drawers 1462 extends rearward (i.e., toward the rear end1404) in the longitudinal direction D1 into the utility space 1472.Therefore, in at least some embodiments, the drawers 1462 may be atleast partially aligned with the rear floor 1430 and the flatbed 1470 inthe longitudinal direction D1 in the opened states 1466 thereof.

In some embodiments, the utility cabinet 1460 directly contacts the wall1416 as indicated above. The wall 1416 illustratively includes, or isotherwise embodied as, a rearwardly-facing exterior wall of the frontcage 1410. The wall 1416 extends in a vertical direction VD to a roof1418 of the front cage 1410 such that the wall 1416 is interconnectedwith the roof 1418. The wall 1416 extends above a top or uppermostsurface 1468 of the utility cabinet 1460 to the roof 1418. The wall1416, the roof 1418, and the top surface 1468 cooperate to define astorage space 1474 that is accessible from, and in fluid communicationwith, the utility space 1472.

The illustrative flatbed 1470 of the vehicle 140 includes sidewalls1476, 1478 arranged opposite one another, a rear gate 1480, a rearbumper 1482, and a vice 1484. Each of the sidewalls 1476, 1478 extendsupwardly away from the rear floor 1430 in the vertical direction VD toat least partially define the utility space 1472. Each of the sidewalls1476, 1478 is formed without an opening extending therethrough. The reargate 1480 extends between the sidewalls 1476, 1478 in a lateraldirection D2 perpendicular to the longitudinal direction D1 to at leastpartially close off the utility space 1472. The rear bumper 1482 extendsrearwardly in the longitudinal direction D1 away from the rear gate1480. The vice 1484 is mounted to the rear bumper 1482.

In the illustrative embodiment, the flatbed 1470 includes a guide rail1486 interconnected with the sidewall 1476. The guide rail 1486 extendsupwardly away from the sidewall 1476 in the vertical direction VD todefine a slot 1488 between the sidewall 1476 and the guide rail 1486. Insome embodiments, the guide rail 1486 provides a handle that may begrasped by a subject to provide stability and/or support when thesubject is positioned in the utility space 1472 or when the subject ispositioned in close proximity to the guide rail 1486 outside the utilityspace 1472. Additionally, in some embodiments, the guide rail 1486provides a structure to which other devices (e.g., utility devices,accessories, or articles disposed in the utility space 1472) may becoupled and/or secured to facilitate transport of those devices in useof the vehicle 140.

In the illustrative embodiment, the flatbed 1470 includes a guide rail1490 interconnected with the sidewall 1478. The guide rail 1490 extendsupwardly away from the sidewall 1478 in the vertical direction VD todefine a slot 1492 between the sidewall 1478 and the guide rail 1490. Insome embodiments, the guide rail 1490 provides a handle that may begrasped by a subject to provide stability and/or support when thesubject is positioned in the utility space 1472 or when the subject ispositioned in close proximity to the guide rail 1490 outside the utilityspace 1472. Additionally, in some embodiments, the guide rail 1490provides a structure to which other devices (e.g., utility devices,accessories, or articles disposed in the utility space 1472) may becoupled and/or secured to facilitate transport of those devices in useof the vehicle 140.

It should be appreciated that a variety of devices may be arrangedand/or transported in the utility space 1472 of the vehicle 140 in usethereof. In the illustrative example of FIG. 14 , a cable spool 1494, atub 1496, and a cooler 1498 are disposed in the utility space 1472. Thecable spool 1494, the tub 1496, and the cooler 1498 may be tied ortethered to one of the guide rails 1486, 1490, at least in someembodiments. Of course, in other embodiments, other devices may bepositioned in the utility space 1472 and secured to one of the guiderails 1486, 1490 depending on the particular mission or application ofthe vehicle 140.

In some embodiments, the flatbed 1470 includes a bench 1495 arranged inthe utility space 1472 and supported by the rear floor 1430. Theillustrative bench 1495 is disposed beneath the utility cabinet 1460 inthe vertical direction VD. As a result, the drawers 1462 of the utilitycabinet 1460 may be opened and closed without interference with thebench 1495. In some embodiments, the bench 1495 may be aligned in thevertical direction VD with a base (not shown) of the utility cabinet1460 located beneath the drawers 1462.

The illustrative bench 1495 includes a leg 1497 arranged to extendlaterally through the utility space 1472 in the lateral direction D2.The bench 1495 also includes a leg 1499 interconnected with the leg 1497that is arranged to extend longitudinally through the utility space 1472in the longitudinal direction D1. In some embodiments, the leg 1497extends laterally through the utility space 1472 over an entire width Wof the utility space 1472. In other embodiments, the leg 1497 extendslaterally through the utility space 1472 over part of the width W of theutility space 1472. In some embodiments, the leg 1499 extendslongitudinally through the utility space 1472 over an entire length L ofthe utility space 1472. In other embodiments, the leg 1499 extendslongitudinally through the utility space 1472 over part of the length Lof the utility space 1472.

In the illustrative embodiment, the intermediate section 1450 has afixed, single length (i.e., in the longitudinal direction D1) and is notadjustable to vary the length thereof. The intermediate section 1450includes at least one reinforcement beam 1452 that extends between theroof 1418 and the flatbed 1470. More specifically, the illustrativereinforcement beam 1452 is interconnected with the roof 1418 at one end1454 thereof and interconnected with the sidewall 1476 at another end1456 thereof opposite the end 1454. In some embodiments, theintermediate section 1450 may include another reinforcement beam (notshown) that is interconnected with the roof 1418 at one end thereof andinterconnected with the sidewall 1478 at another end thereof oppositethe one end.

The illustrative reinforcement beam 1452 extends oblique to the sidewall1476 to define an obtuse angle α between the reinforcement beam 1452 andthe sidewall 1476. In the illustrative embodiment, the reinforcementbeam 1452 is directly interconnected with the guide rail 1486. Morespecifically, the reinforcement beam 1452 is directly interconnectedwith the guide rail 1486 in close proximity to an alcove 1458 of theintermediate section 1450.

The reinforcement beam 1452 at least partially defines the alcove 1458of the intermediate section 1450. The alcove 1458 is disposed at leastpartially between the front cage 1410 and the rear floor 1430 in thelongitudinal direction D1. The alcove 1458 is illustratively alignedwith the utility cabinet 1460 in the longitudinal direction D1. In theillustrative embodiment, the alcove 1458 defines an opening 1459 intothe intermediate section 1450 in the lateral direction D2. The opening1459 is closed off from the operator cabin 1412. In some embodiments,the alcove 1458 includes, or is otherwise embodied as, a nook accessiblefrom the utility space 1472 or from outside the vehicle 140 in closeproximity to the intermediate section 1450. Additionally, in someembodiments, the alcove 1458 provides an exterior compartment forstoring items, such as a fire extinguisher, for example.

In the illustrative embodiment, the front cage 1410 includes doors 1420,1422 arranged on a driver side 1424 of the vehicle 140. It should beappreciated that corresponding doors (not shown) are arranged on apassenger side 1426 of the vehicle 140 disposed opposite the driver side1424. The doors 1420, 1422 are illustratively arranged between the frontend 1402 of the vehicle 140 and the alcove 1458 in the longitudinaldirection D1. The door 1420 is positioned forward of the door 1422 inthe longitudinal direction D1. The doors 1420, 1422 and the doorsdisposed on the passenger side 1426 cooperate to at least partiallydefine the operator cabin 1412, which is configured to accommodate sixpassengers as indicated above.

The illustrative vehicle 140 includes a monocoque 1406 that at leastpartially defines the front cage 1410, the rear floor 1430, theintermediate section 1450, and the flatbed 1470. The monocoque 1406illustratively includes, or is otherwise embodied as, a single-piece,monolithic structure unsupported by an internal chassis. Putdifferently, the monocoque 1406 does not include an internal chassis, atleast in some embodiments. The monocoque 1406 has a compositeconstruction such that the front cage 1410, the rear floor 1430, theintermediate section 1450, and the flatbed 1470 are formed from one ormore composite materials. In some embodiments, the monocoque 1406 hasthe composite structure 700 described above. Additionally, in someembodiments, the monocoque 1406 does not include metallic material.

Referring now to FIG. 15 , the two-passenger flatbed utility vehicle 110shown in FIG. 1 is depicted in greater detail. It should be appreciatedthat the illustrative vehicle 110 is an electric vehicle as mentionedabove. In the illustrative embodiment, the vehicle 110 includes a frontcage 1510, a rear floor 1530, an intermediate section 1550, and aflatbed 1570. The front cage 1510 at least partially defines an operatorcabin 1512 of the vehicle 110. The rear floor 1530 is positionedrearward of the front cage 1510 in a longitudinal direction D1′. Theintermediate section 1550 is disposed at least partially between thefront cage 1510 and the rear floor 1530 in the longitudinal directionD1′. The flatbed 1570 is at least partially defined by the rear floor1530 and open to the ambient environment. The flatbed 1570 defines autility space 1572 that is located outside the operator cabin 1512 andaccessible from a rear end 1504 of the vehicle 110.

The illustrative vehicle 110 may be formed from the monocoque system 900and/or the modular mold system 800 described herein. The front cage 1510may be formed from the front cage mold unit 810, the rear floor 1530 andthe flatbed 1570 may be formed from the rear floor mold unit 820, andthe intermediate section 1550 may be formed from one of the intermediatemold units 832, 834, 836, at least in some embodiments. Additionally, insome embodiments, the front cage 1510 may be formed from the front cagemold unit 810 having the shape and structure of the mold unit 910, therear floor 1530 and the flatbed 1570 may be formed from the rear floormold unit 820 having the shape and structure of the mold unit 920, andthe intermediate section 1550 may be formed from one of the intermediatemold units 832, 834, 836 having the shape and structure of thecorresponding units 932, 934, 936.

The illustrative flatbed 1570 of the vehicle 140 includes sidewalls1576, 1578 arranged opposite one another, a rear gate 1580, and a rearbumper 1582. Each of the sidewalls 1576, 1578 extends upwardly away fromthe rear floor 1530 in the vertical direction VD′ to at least partiallydefine the utility space 1572. Each of the sidewalls 1576, 1578 isformed without an opening extending therethrough. The rear gate 1580extends between the sidewalls 1576, 1578 in a lateral direction D2′perpendicular to the longitudinal direction D1′ to at least partiallyclose off the utility space 1572. The rear bumper 1582 extendsrearwardly in the longitudinal direction D1′ away from the rear gate1580.

In the illustrative embodiment, the flatbed 1570 includes a guide rail1586 interconnected with the sidewall 1576. The guide rail 1586 extendsupwardly away from the sidewall 1576 in the vertical direction VD′ todefine a slot 1588 between the sidewall 1576 and the guide rail 1586. Insome embodiments, the guide rail 1586 provides a handle that may begrasped by a subject to provide stability and/or support when thesubject is positioned in the utility space 1572 or when the subject ispositioned in close proximity to the guide rail 1586 outside the utilityspace 1572. Additionally, in some embodiments, the guide rail 1586provides a structure to which other devices (e.g., utility devices,accessories, or articles disposed in the utility space 1572) may becoupled and/or secured to facilitate transport of those devices in useof the vehicle 110.

In the illustrative embodiment, the flatbed 1570 includes a guide rail1590 interconnected with the sidewall 1578. The guide rail 1590 extendsupwardly away from the sidewall 1578 in the vertical direction VD′ todefine a slot 1592 between the sidewall 1578 and the guide rail 1590. Insome embodiments, the guide rail 1590 provides a handle that may begrasped by a subject to provide stability and/or support when thesubject is positioned in the utility space 1572 or when the subject ispositioned in close proximity to the guide rail 1590 outside the utilityspace 1572. Additionally, in some embodiments, the guide rail 1590provides a structure to which other devices (e.g., utility devices,accessories, or articles disposed in the utility space 1572) may becoupled and/or secured to facilitate transport of those devices in useof the vehicle 110.

It should be appreciated that a variety of devices may be arrangedand/or transported in the utility space 1572 of the vehicle 110 in usethereof. Such devices may include the devices 1494, 1496, 1498 describedabove with reference to FIG. 14 , which may be tied or tethered to oneof the guide rails 1586, 1590, at least in some embodiments. Of course,in other embodiments, other devices may be positioned in the utilityspace 1572 and secured to one of the guide rails 1586, 1590 depending onthe particular mission or application of the vehicle 110.

In the illustrative embodiment, the intermediate section 1550 has afixed, single length (i.e., in the longitudinal direction D1′) and isnot adjustable to vary the length thereof. The intermediate section 1550includes at least one reinforcement beam 1552 that extends between theroof 1518 and the flatbed 1570. More specifically, the illustrativereinforcement beam 1552 is interconnected with the roof 1518 at one end1554 thereof and interconnected with the sidewall 1576 at another end1556 thereof opposite the end 1554. In some embodiments, theintermediate section 1550 may include another reinforcement beam (notshown) that is interconnected with the roof 1518 at one end thereof andinterconnected with the sidewall 1578 at another end thereof oppositethe one end.

The illustrative reinforcement beam 1552 extends oblique to the sidewall1576 to define an obtuse angle B between the reinforcement beam 1552 andthe sidewall 1576. In the illustrative embodiment, the reinforcementbeam 1552 is directly interconnected with the guide rail 1586. Morespecifically, the reinforcement beam 1552 is directly interconnectedwith the guide rail 1586 in close proximity to an alcove 1558 of theintermediate section 1550.

The reinforcement beam 1552 at least partially defines the alcove 1558of the intermediate section 1550. The alcove 1558 is disposed at leastpartially between the front cage 1510 and the rear floor 1530 in thelongitudinal direction D1′. In the illustrative embodiment, the alcove1558 defines an opening 1559 into the intermediate section 1550 in thelateral direction D2′. The opening 1559 is closed off from the operatorcabin 1512. In some embodiments, the alcove 1558 includes, or isotherwise embodied as, a nook accessible from the utility space 1572 orfrom outside the vehicle 110 in close proximity to the intermediatesection 1550. Additionally, in some embodiments, the alcove 1558provides an exterior compartment for storing items, such as a fireextinguisher, for example.

In the illustrative embodiment, the front cage 1510 includes a door 1520arranged on a driver side 1524 of the vehicle 110. It should beappreciated that a corresponding door (not shown) is arranged on apassenger side 1526 of the vehicle 110 disposed opposite the driver side1524. The door 1520 is illustratively arranged between the front end1502 of the vehicle 110 and the alcove 1558 in the longitudinaldirection D1′. The door 1520 and the door disposed on the passenger side1526 cooperate to at least partially define the operator cabin 1512,which is configured to accommodate two passengers as indicated above.

The illustrative vehicle 110 includes a monocoque 1506 that at leastpartially defines the front cage 1510, the rear floor 1530, theintermediate section 1550, and the flatbed 1570. The monocoque 1506illustratively includes, or is otherwise embodied as, a single-piece,monolithic structure unsupported by an internal chassis. Putdifferently, the monocoque 1506 does not include an internal chassis, atleast in some embodiments. The monocoque 1506 has a compositeconstruction such that the front cage 1510, the rear floor 1530, theintermediate section 1550, and the flatbed 1570 are formed from one ormore composite materials. In some embodiments, the monocoque 1506 hasthe composite structure 700 described above. Additionally, in someembodiments, the monocoque 1506 does not include metallic material.

While the disclosure has been illustrated and described in detail in theforegoing drawings and description, the same is to be considered asexemplary and not restrictive in character, it being understood thatonly illustrative embodiments thereof have been shown and described andthat all changes and modifications that come within the spirit of thedisclosure are desired to be protected.

What is claimed is:
 1. An electric vehicle comprising: one or moreelectric motors; a front cage at least partially defining an operatorcabin; a flatbed positioned rearward of the front cage in a longitudinaldirection that is open to the ambient environment and defines a utilityspace located outside the operator cabin; a utility cabinet including aplurality of drawers accessible from the utility space; and a monocoquethat at least partially defines the front cage and the flatbed.
 2. Theelectric vehicle of claim 1, wherein the monocoque is formed fromcomposite materials.
 3. The electric vehicle of claim 1, wherein theutility cabinet extends forward in the longitudinal direction to thefront cage.
 4. The electric vehicle of claim 3, wherein the utilitycabinet extends at least partially into the operator cabin.
 5. Theelectric vehicle of claim 3, wherein: the utility cabinet directlycontacts a rearwardly-facing exterior wall of the front cage that isinterconnected with a roof of the front cage; and the exterior wall, theroof, and an uppermost surface of the utility cabinet in a verticaldirection cooperate to define a storage space accessible from theutility space.
 6. The electric vehicle of claim 1, further comprising anintermediate section disposed at least partially between the front cageand the flatbed in the longitudinal direction, wherein: the intermediatesection includes an alcove aligned with the utility cabinet in thelongitudinal direction; the alcove defines an opening into theintermediate section in a lateral direction perpendicular to thelongitudinal direction; and the opening is closed off from the operatorcabin.
 7. The electric vehicle of claim 1, further comprising anintermediate section disposed at least partially between the front cageand the flatbed in the longitudinal direction, wherein: the flatbedcomprises a first sidewall that extends upwardly away from a rear floorof the vehicle in a vertical direction to at least partially define theutility space and a second sidewall arranged opposite the first sidewallthat extends upwardly away from the rear floor in the vertical directionto at least partially define the utility space, and the intermediatesection includes a reinforcement beam that is interconnected with a roofof the front cage at one end thereof and interconnected with one of thefirst sidewall and the second sidewall at another end thereof oppositethe one end.
 8. The electric vehicle of claim 7, wherein thereinforcement beam extends oblique to the one of the first sidewall andthe second sidewall to define an obtuse angle between the reinforcementbeam and the one of the first sidewall and the second sidewall.
 9. Theelectric vehicle of claim 7, wherein: the reinforcement beam at leastpartially defines an alcove of the intermediate section that is disposedat least partially between the front cage and the flatbed in thelongitudinal direction; and the alcove defines an opening into theintermediate section in a lateral direction perpendicular to thelongitudinal direction.
 10. The electric vehicle of claim 7, wherein:the flatbed comprises a first guide rail interconnected with the firstsidewall that extends upwardly away from the first sidewall in thevertical direction to define a first slot between the first sidewall andthe first guide rail and a second guide rail interconnected with thesecond sidewall that extends upwardly away from the second sidewall inthe vertical direction to define a second slot between the secondsidewall and the second guide rail; and at least one of the first guiderail and the second guide rail is directly interconnected with thereinforcement beam.
 11. The electric vehicle of claim 7, wherein theflatbed comprises: a rear gate that extends between the first sidewalland the second sidewall in a lateral direction perpendicular to thelongitudinal direction to at least partially close off the utilityspace; a rear bumper extending rearwardly in the longitudinal directionaway from the rear gate; and a vice mounted to the rear bumper.
 12. Amethod of making an electric vehicle, the method comprising: forming amonocoque of the electric vehicle; supporting at least one electricmotor of the electric vehicle using the monocoque; and supporting autility cabinet including a plurality of drawers using the monocoque,wherein forming the monocoque comprises: defining a front cage thatprovides an operator cabin, defining a flatbed positioned rearward ofthe front cage in a longitudinal direction that is open to the ambientenvironment and a defines a utility space located outside the operatorcabin.
 13. The method of claim 12, wherein supporting the utilitycabinet using the monocoque includes positioning the utility cabinet inthe flatbed such that the utility cabinet is accessible from the utilityspace.
 14. The method of claim 12, wherein forming the monocoqueincludes forming the monocoque from composite materials.
 15. The methodof claim 12, wherein forming the monocoque comprises defining anintermediate section disposed at least partially between the front cageand the flatbed in the longitudinal direction.
 16. The method of claim15, wherein defining the intermediate section comprises forming analcove aligned with the utility cabinet in the longitudinal directionthat defines an opening into the intermediate section in a lateraldirection perpendicular to the longitudinal direction.
 17. The method ofclaim 16, wherein forming the alcove comprises closing off the openingfrom the operator cabin.
 18. The method of claim 15, wherein: definingthe flatbed comprises providing (i) a first sidewall that extendsupwardly away from a rear floor of the monocoque in a vertical directionto at least partially define the utility space and (ii) a secondsidewall arranged opposite the first sidewall that extends upwardly awayfrom the rear floor in the vertical direction to at least partiallydefine the utility space; and defining the intermediate sectioncomprises forming a reinforcement beam and interconnecting thereinforcement beam (i) with a roof of the front cage at one end thereofand (ii) with one of the first sidewall and the second sidewall atanother end thereof opposite the one end.
 19. The method of claim 18,wherein interconnecting the reinforcement beam with the roof of thefront cage and the one of the first sidewall and the second sidewallcomprises defining an obtuse angle between the reinforcement beam andthe one of the first sidewall and the second sidewall.
 20. The method ofclaim 18, wherein forming the reinforcement beam comprises at leastpartially defining an alcove of the intermediate section that isdisposed at least partially between the front cage and the flatbed inthe longitudinal direction and provides an opening into the intermediatesection in a lateral direction perpendicular to the longitudinaldirection.